Process of making one-piece radiator-sections.



' F. A. FBLDKAMP. PROCESS OF MAKING ONE PIECE RADIATOR SEGTIO APPLICATION FILED DI JO. 5. 1910.

Patented July 11, 1911.

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F. A. FELDKAMP. PROCESS OF MAKING ONE PIECE RADIATOR SECTIONS.

APPLICATION r-rnnn' DBO. a. 1910.

Patented Jul 11., 1911.

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WITkNESSES: wmfi INVENTOR UV, mm m M E a B M n E F W pm resur rricn.

FREDERICK-A. FELDKAMP, or VAILSBURG, NEW JERSEY, assrelvon TO ELECTROLYTIC rnonucrs 00;. a oonrona'rron or nnwonnsnv.

PROCESS OF MAKING ONE-PIECE RADIATOB-SECTIONS 997,768. Original application filed September To' al l whom 'it may-concern."

Be itknown that I, FREDERICK A. FELD- Kit-Mr, c'itiaen of the United States, residing at .Vailsburg, 1n the countyofEFSex and State of New Jersey, have invented certainnew and useful Improvements in Processes of Making One-Piece Radiator-Sections; and I do hereby declare the following to be a full, clear, and exact description of the invention, such as will enable others skilled in the art to which it appertains to ma-ke'and .use the same, reference belng had to the accompanying drawings, and to characters of reference marked thereon, which form a part of this specification.

The present invention. relates, generally,

to a novel process or method of producingradiator-sections for automobiles, each section being made by electro-deposition of metal and being formed in a single-integral mass of metal in the form of a hollow honeyof radiating surfacesis exposed to the coolin; action of the air. I

A further object of this invention is to provide a process of the character hereinafter set forth, in which there is secured by the use of the said process a radiator-sec- 'tion" in the. form of a finely sub-divided honey-comb section or element having all of its wall-portions of a uniform thickness.

With the objects of this invention in .view, the said invention eonsists. primarily, in a process for producing a. hollowhoney-comb one-pi;?ce radiator-section, in which a core or pattern (if-a fusible metal is first provided with multiplicity of small and closely located: holes or openings, of any desirable configuration, then by electro-(leposition de positing a metal first upon those surfaceportions of-the core or pattern forming said holes or openings directly within the interior of said holes or openings and out- Specification of Letters Patent.

Patented July '11, 19H.

15, 1910, Serial No.'5 82,110. Divided and this application filed Decemher 5, 1910. Se riaINo. 595,831.

.wardly toward the outer faces .of the said core or pattern, and then removing the said core or pattern from within the said electrolytically deposited metal.

The said invention consists, furthermore, in adding to the steps of the process just .set forth, after the said electrolytic deposition of metal from the interior'of the holes iiopenings of the core or patterutoward the outer surfaces of the core or pattern, a further step of depositing by electro-deposition,'metal upon the outer faces of the core or pattern, and inwardly into the said holes or openings and upon the previously deposited metal therein, and then removing the said core or pattern from within the said electrolytically deposited metal.

Other objects of this invention not at this time more particularly mentioned will be clearly understood from the following detaileddcscription of the same.

The inventioinis clearly illustrated in the accompanying drawings, in which 2-- Figure 1 is a front view of a. fusible core or pattern employed in the process ormethod of making radiator-sections according to the pr nciples of the present invention and Fig. 2 is a horizontal sectional representa tion, on an enlarged scale, of a portion of said fusible core or pattern. Fig. 3 is a rear face view of a portion of an insulating material or shadower employed with the herein described process; and Fig. 4 is a sectional representation of the same, said section being taken on line 44 in said Fig. 3, looking in the direction of the arrow at. Fig. 5 is a transverse sectional representation, on a considerably enlarged scale, of a.

portion of the fusible core or pattern and the shadower, said view showing the manner of using the shadower with said core or pattern, and said-view showing in addition,

and in section, the first electrolytic deposit of metal, deposited in the interior of the holes or openings of the shadower, and from the interior of said holes or openings toward the outer faces of the fusible core or pattern. I 6 isa similar sectional representation of said portion of the core orpattern and the said first electrolytic. deposit of metal after the shadower has been removed. representation of a portion of the fusib le core or pattern with the first electrolytic Fig. 7 is a transverse sectional deposit of metal, and a second electrolytic deposit of metal from the outer faces of the said core or pattern inwardly into said holes or openings and upon the said first electrolytic deposit of metal, said view showing a uniform thickness throughout all the parts of the electrolytically deposited metal. Fig. 8 is a sectional representation of a portion of the finally completed hollow honey- -ings, each hole or comb and one-piece section or element for an automobile-radiator, said views showing the fusible metal removed from said section.

The herein-above described drawings illnstrate the results obtained-during the diflerent stages of procedure in carrying out the novel process or method embodying the principles of the present invention, this process or method comprising the following steps :-I first prepare a core or pattern of any suitable configuration and of a suitable metal which is capable of melting or fusing at a-comparatively low temperature or degree of heat. The said fusible core or pattern is cast in a suitable mold, and when completed has the general form and appearance, represented in said Figs. 1 and 2 of the drawings, the said core or pattern, in the form of a plate, being indicated by the reference-character 1, and the body portion of the same being provided with a great many holes or openings, as 2, closely adjacent to one another and arranged in symmetrical lines. These holes or openings 2, as will be seen more particularly from an inspection of Fig. 2 of the drawings, are preferably of smaller cross-sectional area at their inner central portions than at their ends, so that the holes taper in opposite directions, in the manner shown; but, it will be understood that the holes or openings may not necessarily be made tapering as here shown. As illustrated, in proportion to the size of the core or pattern as a whole, the said holes or openings are made quite large, but in practice each hole or opening is small, since in the practical core or pattern, used in my novel process, the bodyportion of the core or pattern contains from nine thousand to ten thousand holes or openopcning being usually thrce-sixtcenths of an inch in diameter, and the, holes or openings being spaced onequarter of an inch apart, from center to center. lt will be understood, however, that by means of the proccss hcrein described, the holes or openings may be made even smaller and they may be. more closely placed with relation to one another. lhc uppcr part of the said core or pattern is formed with a blank space 3 of suitable configuration for providing a top water-collecting space or chamber in the finished radiator-scction to be produced; and in like manner. the lower part of the said core or pattern is formed with a blank space 4: of suitable configuration for providing a bottom water-collecting portion of said core or pattern located between the licrcin-above mentioned, holes or opcningsQ provide suitable core-portions or members by means of which are produced the necessary water-conveying channels or ducts of the finished radiatorscction. After the core or pattern has thus been produced, the same is ready for its immersion in an electrolytic solution, by thoroughly cleaning its surfaces by mechanical brushing, or otherwise, the application of a chemical Wash, and, finally, by rinsing in a water bath'to remove all dirt and grease that may adhere to its surfaces.

The shadower 5 to be presently described as to its detailed construction, is now arranged upon the various outer faces and the surrounding end-surfaces of the core or pattern, that is the two sides, the top, the bottom, and the two ends, substantially in the manner indicated in Fig. 5 of the drawings. Referring now' to said Fig. 5, the said shadower consists of a pair of insulating sheets 6, preferably of celluloid, or some other similar material. These sheets conform at their marginal edges with the conformation of the peripheral edges of the said core or pattern, the said sheets being placed one upon either side of the core or pattern. A pair of band-like members, as 7 and 8, or other suitable means, made also from celluloid, or other similar material, are arranged about-the two end-surfaces, and the top and bottom of the core oi pattern, as will be evident from an inspection of said Fig. 5 of the drawings, the ar'angement of the said sheets 6 and the said band-like members 7 and 8 thus entirely inclosing thesaid core or pattern. Asshown, the said sheets 6 s are each provided with a plurality of holes" or openings 9 which correspond in number and position to the holes or openings 2 in the core or pattern 1, so that when the said insulating sheets 6 are assembled in the manner stated with relation to the said core or pattern,the said holes or openings 9 of the 1 said insulating sheets-t3 will register, respectively, with the corresponding holes or openings 2 in the core or pattern. 1. The said holes or openings 9 are smaller than the holes or opeuingsEZ, and each hole or open ing 7 is surrounded by an inwardly extending annular; tlange or projection, as 10, so as to provide tubular extensions which, when the said sheets (5 are placed upon the opposite faces of'the fusible core orpattern, extend some little distance into the said holes or openings 2. in the manner clearly illustrated in said Fig. 3 of thedrawings.

The core or pattern which has thus been incloscd in an in ulatiing jacket or coating, is now ready for thc elcctroplating bath, in

The said insulating jacket or coating while it protects the outer surfaces of the fusibl core or pattern from recelving a coating 0 metal by electro-deposition, still permits, by virtue of its holes or openings 9, with their respective tubular portions or projections 10, the passage ofthe current in the electrolyte into and through said tubuIarportiOnS or projections 10, so that an electrolytic'ac tion, may continue and build up a first me- .tallic deposition or plating upon the interiorly exposed surface-portions of the core or pattern 1 from within its holes or openings 2. The said tubular portions or projections l0,tend to concentrate the electro lytie action upon a point centrally located within the said holes or openings 2, so that the plating action of the first metallic dep-.

osition or plating is strongest atthat point, and continues with decreasing force, 1110111:-

ward directions toward the outer faces of the core or pattern and the respective marginal edges of the said holes or openings 2.

In this manner, the hollow shell formed by.

the metallic deposition or plating is built upwvithin the said holes or openings so that the deposited metal will taper in opposite directions, as shown, being of the heaviest deposit within the interior central part of eachzhole or opening 2, and being of the least thickness at the marginal edge of the hole or opening. The fusible core or pattern 1, with this first deposit of metal plated thereon, is now taken from the electroplating bath and the core or pattern is stripped ofv-its insulating-jacket or core: The next step in the process is to again immerse the said core or pattern with said first deposit or plating of metal thereon as above de scribed, in. the electro-plating bath. The result is that a deposit of metal is now electroplated upon all of theouter exposed sur faces of the core or pattern, the metal deposit building up upon said surface to the required thickness, and at the same time depositing upon the first deposit or plating of metal from the outside and in opposite directions toward the middle of the previthe electro-plating step is finally completed, the combined thicknesses of the two d'EPOSl'E- ing steps of metal within the holes or openings will be uniform throughout, and will be the same as the thickness of the deposited or plated metal upon anypart of the outer surface-portions of the core or pattern 1,

as clearly indicated in Fig. 7 of the drawings, in which this I uniform deposit or that it melts at a plating of metal is indicated by the referencecharacter 11, the dotted lines 12 indicating the extent of the first metallic deposition or plating extends in directions from within the interior central portions of the holes or openings toward and stopping at the outer surfaces of the sides of the core or pattern, with decreasing electrolytic activity, whereas the second metallic deposition or plating extends from the outer faces of the core or pattern and 'into the holes or perforations, with decreasing electrolytic activity within and toward the middle portions/ of said holes or openings, to produce a uniform thickness of the deposited metal, as has been stated, and the said second deposit of metal practically embracing the said first deposit of metal, so that the second deposit of metal forms a lock withrelation to said first deposit of metal.

After the second deposition or plating of the metal has been finishedpthe core or pattern with the completed metallic deposition thereon is removed from the electroplating bath, is washed so as to remove any adhering electrolyte, and is then dried. The final step of the process is to subject the said core or pattern with the completedmetallic deposition to the action of heat, by placing the same in a suitable gas-chamber or oven; or, by other'suitable means, for producing the required temperature, for melting out the fusible core and leaving the hollow and honey-combedshell of the radiator-section. The melting or fusing point of the metal of which the core or pattern is made, is such low degree of heat, the melting or fusing metal running out of and away from the completed metallic deposition without in any way injuring said dep: osition of metahand thus leaving the.hol-

low and honey-comb shelLlB, indicated more particularly in Fig. 8 of the'drawings.

To recapitulate the various steps of'my novel process hereinabove described in detail, the same consists fir'st,- of preparing. a

core or pattern of metal capable of receiving electrolytic deposition, and capable of meltv mg or fusing at a low temperature; .sec

ondly, providing the same with a perforated insulating jacket or envelop; thirdly, 1mmersing the same in an electro-plating bath and depositing by electro-depositionmetal within the hoies or openings with which the core or' pattern has been provided, electro-deposition of metal decreasing, in thickness or amount from the central interior portions of said holes or openings toward the outer edges of the holes or open ings; fourthly. removing the coreorpattern and the'metahdeposited or plated thereon from the electroplating bath, and stripping oil the insulating jacket .or envelop; fifthly,

I from the electro-plating bath; and finally,

washing said metallic deposition or plating of metal, and subjecting the same'with its fusible core therein to the action of heat, so as to melt said core or pattern and removing it from the hollow shell formed by said metal depositions or platings.

lcluilil2-- l. A process r'or iroducing hollow honeycomb oncpicce rat iator-sections consisting of first preparing a core or pattern of a fusible metal with openings, then by olcctro deposition de 'iositing a metal first upon the snrtwo-portions of the core or pattern within thrsaid openings and outwardly toward the outer faces of said core or pattern, and then removing said core or pattern from said tltf'li' )l \'ll itlly deposited metal.

2. A process for producing hollow honeyvomh onc- 'iiecc radiator-sections consisting of lirst. preparing a core or pattern of a fusible metal with openings, then by electroilt-position depositing a metal first upon the sortace-portions of the core or pattern within the said openings and outwardly toward the outer faces of said core or pattern; then prot'lucing a second electrolytic deposition of metal from theoutcr edge-portions of the said omnings toward the middle-portion of cat'li opening, and finally removing said core or pattern from said electrolytically dcpositcd metal,

3. A. process for producing hollow honeycomb one-piece radiator-sectionsconsisting of first prcpa ring a core or pattern of a fusible metal with openings, then by electrodeposition depositing a metal first upon the s1u-tat'zc-portions of the core or pattern within the said openings and outwardly toward the outer faces of said core or pattern, then producing an electrolytic deposition of metal upon the outer sin'face-portions of the said core or pattern and from the opposite faces thereof into the said openings from the marginal edge-portions thereof to the middle portion of each opening, and finally remo\ ing said core or pattern from said electrol tically deposited. metal.

4.. A process for producing hollow honeycomb oncpi'c-e radialor-sc('timis consisting in first preparing a core or pattern of a lusible metal with a series of openings, then producing electrolytically a deposit of metal into the interior of said openings and outwardly therefrom toward the outer faces of said core or pattern, then producing electrolytically another deposit of mctal upon the outer faces of the core or pattern and inwardly into and toward the middle of said openings, and finally removing said core or pattern from said electrolytically deposited metal. y 5. A process for producing hollow honeycomb one-piece radiator-sections consisting in first preparing a core or pattern of a fusible metal with a series of openings, then producing electrolytically a deposit. of metal into the interior of said openings and'outwardly therefrom toward the outer faces of said core or pattern, then producing electrolytically another deposit of metal upon the outer faces of the core or pattern and inwardly into and toward the middle of said openings, and finally applying heat for melting said core or pattern out of said electrolytically deposited metal.

6. A process for producing hollow honeycomb one-piece radiator-sections consisting in first preparing a core or pattern of a metal fusible at a low temperature with a multiplicity of small holes or openings, protecting the outer surface-portions of the core or pattern against electrolytic action, then producing electrolytically a deposit of metal within the holes or openings in said core or pattern and toward the marginal,edgc-portions of said holes or openings, then. removing from the outer surface-portions of the core or pattern the protegting means against plating, then producing electrolytically another deposit of metal upon the outer surface-portions of the core or pattern and in-' wardly and toward the middle of said holes or openings, and finally removing core or pattern from said electrolytically deposited nietal so as to leave a hollow honeycomb shcll.

7. A process for rodueing hollow honeycomb one-piece ra'iator-scctions consisting in first preparing a core or pattern of a metal fusible at a low temperature'with a multiplicity of small holes or openings, protee/ting. the outer surface-portions of the core or pattern against electrolytic action, then producing electrolytically a deposit of metal within the holes or openings in'said core or pattern and toward the marginal edge-port-ions of said holes or openings, then removing from the outer surface-portions of the core or pattern the protecting means against plating, then producing electrolytically another deposit of metal upon the outer surface-portions of the core or pattern and inwardly and toward the middle of said holes or openings, and finally applying heat for melting said core or pattern out of said elec- 8. A process for producing hollow honey comb one-piece radiator-sections consisting in first making a core or pattern of a metal fusible at low temperature, providing the same with small holes-or openings set close together, providing an insulating covering formed with holes or openings corresponding' in position with the holes or openings in said core or pattern, arranging said covering 5 upon the outer exposed surface-portions of said core or pattern to protect the said exposed surface-portions of the core or pattern against electrolytic action, providing means in connection with each hole or opening in said insulating covering for directing operation of the electrolytic action to a central point wi hin the holes or openings in said core or pattern to cause the electrolytic action to operate with diminishing efiiciency outwardly from the central inner portion of each hole or opening of the core or pattern to 'ard the outermarginal edge-portions of said holes or openings, continuing said electrolytic action under such conditions to provide a continued metallic deposition within the holes or openings of said core or pattern, then removing said insulating covering, then producing electrolytically another deposit of metal upon the outer surface-por tions of the core or pattern and inwardly into the said holes. or openings in said core or pattern with diminishing efficiency inwardly toward the inner central portion of each hole or opening of the core or pattern and upon the first electrolytic deposit of metal within said holes or openings, and finally removing said core or pattern from said complete electrolytic deposition, so as to leave a hollow honey-comb shell of a' uniform thickness of metal throughout any parts of its walhportions.

9. A process for producinghollow honeycomb one-piece radiator-sections consisting in first making a core or pattern of a metal fusible at low temperature, providing the same with small holes or openings set close together, roviding an insulating covering formed with holes or openings corresponding'in position with the holes or openings in said core or pattern. arranging said covering upon the outer exposed surface-portions of said core or pattern to protect the said exposed surface-portions of the core or pattern against electrolytic action. further pro viding said insulating covering with inwardly extending tubular members or projections of smaller diameters than those of the said holes or openings in the core or pattern, arranging said insulating covering upon the respective faces of the core or pattern with the said tubular members or projections extending inwardlyinto the said holes or openings in the core or pattern, for directing the operation of the t l'ectrolytic action to a. central point within the holes or openings in said core or pattern to cause the electrolytic action to operate with diminishing eliicieney outwardly from the central inner portion of each hole or opening of the core or pattern toward the outer marginal edge-portions of said holes or openings, con tinuing said electrolytic action under such conditions to provide a continued metallic deposition within the holes or openings of said core or pattern. then removing said insulating covering. then producing electrolytically another deposit of metal upon the outer surface-portions of the core or pattern and inwardly into the said holes or openings in said core or pattern with diminishing etlieieney inwardly toward the inner central portion of each hole or opening of the core or pattern and upon-the first electrolytic deposit of metal. within said holes or openings and finally removing said core or pattern from the electrolytic solution and melting outsaid core or pattern, so as to leave a hollow honey-comb shell of a uniforin thickness of metal throughout any parts of its wall-portions.

Tn testimony that I claim the invention set forth above Ihave hereunto set my hand this 2nd day of December, 1910. 

